Abstract: A method is described for continuously casting an ingot of a metal alloy of a type having a substantial liquidus-solidus temperature range to produce internal microstructure of a desired fineness. Molten alloy is flowed along an electron beam heated skulled hearth while controlling the electron beam to maintain a solids content in the alloy on the hearth of between about 15% and about 40%. The alloy is poured from the hearth into the top of a continuous casting mold at a rate which produces a thixotropic region at the upper end of the fully solidified alloy in the mold. The ingot produced is characterized by a macrostructure in excess of one millimeter average grain dimensions with a non-uniform shape, orientation, and distribution, and is characterized by a microstructure of the order of fifty micron cell spacing of dendritic crystallites comprising the microstructure.

Abstract: A tiltable cooled crucible for containing the molten alloy has a spout for extracting the molten alloy. The alloy is cast on an advanceable chilled surface. The cooled crucible is protected from the molten alloy by a solidified layer of the alloy which is solidified and prevents reaction between the molten alloy and the cooled crucible.

Abstract: Method and apparatus for producing a fine-grain ingot are disclosed. A feedstock stick is melted to produce a series of fully molten drops which falls on the upper surface of an ingot being formed, to cover a portion thereof which is substantially less than the ingot's total upper surface. The mold is moved laterally with respect to the feedstock stick at a rate which is high enough so that the molten metal impinges upon different portions of the ingot's upper surface but which is low enough to prevent a substantial centrifugally outward flow of the metal impinging on the upper surface of the ingot. The molten metal melt rate is so selected that the impact region on the ingot's upper surface is at or below the solidus temperature of the alloy and above a temperature at which metallurgical bonding with the successive impinging metal can occur.

Abstract: A method of controlling relative movement between an ingot and a mold consists of monitoring the level of the metal pool in the mold by measuring the voltage between the ingot and a mold section disposed above the metal pool, in contact with the bath of molten slag and insulated electrically from the ingot and from the ingot-forming mold section; comparing an instantaneous value of said voltage with a predetermined value and varying the relative speed of the ingot and the mold depending on a signal proportional to the difference between the instantaneous and the predetermined values of said voltage so that the predetermined level of the metal pool is restored.

Abstract: A process for electromagnetically containing and forming molten material into a desired thin strip shape. At least two inductors are employed which are powered at respectively different frequencies. The frequency of the current applied to the upstream inductor is substantially lower than the frequency applied to the downstream inductor thereby providing improved efficiency and reduced power consumption.